Motor Testing System

ESW's Motor Test System is a PC based, turn-key system specifically designed for testing AC or DC motors. It is fully automatic accept/reject tester that isolate the root cause to eliminate redundant failures. This tester simulates the atmosphere that the motors experience during startup and normal operating conditions.

The goal of our testing equipment is to not only catch bad parts, but also to allow you to manage and monitor your equipment processes in a production environment. All tests are completed quickly and accurately without the use of masters. All test steps are automatically sequenced and the decisions relating to the acceptability of the motor under test are made automatically.

To view a video of motor being tested using our test system, click here.

Set-up and Operation

Testing Methods

Testing can include no load, full load (load point test) and/or locked rotor. Parameters tested include hipot leakage, speed (RPM), direction, torque, current, voltage, power, power factor, mechanical power, electrical power, efficiency, and switch cut-out speed. The system is designed to handle most motor applications and the architecture allows customized tests to be easily added.

Loading Methods

There are a variety of different methods we incorporate into our test systems to load the motor, such as hysteresis brakes, eddy current brakes and AC vector drives.

No-Load Methods

No-load testing options include disconnected, inferred no-load and measured no-load.

Torque Measurements

We utilize several methods for determining torque such as trunnion mounting of the loading device, in-line torque transducers or vector drive torque measurement.

Motor Power

Motor power is achieved by a wide range of AC and DC power supplies and regulators are available to provide power to the motor-under-test. The simplest method is to rely solely on the plant power line. Another method is a voltage regulator for supplying regulated power at one or more discreet voltages. Finally, we can also supply sophisticated power supplies which deliver regulated power over a continuously variable voltage and frequency.

Our testers are capable of handling motors from fractional to hundreds of horsepower.

The length for each of the test steps can be individually programmed. Total test time will depend on the motor characteristics and the testing specifications.

Standard Features
  • PC based computer system (Minimum Specifications): 2.4 GHz Pentium 4 processor, MS Windows 2000 operating system, CD ROM drive, 40 Gb hard disk, 256 Meg. RAM, Ethernet network port, video monitor, keyboard and modem.
  • UPS System interfaced for smart shutdown.
  • Hardware based (computer independent) safety shutdown and interlocking.
  • Emergency stop button.
  • Non-Contact Speed Sensor. This sensor measures the motor shaft speed (RPM). The operator will need to install a "cap" fitted with reflective marking on the shaft of the motor.
  • Built in Resistance Standard Calibration Box for automatic calibration of the test system.
  • Automatic set-up of all test limits. Individual limits will be stored in a separate part file for each part number.
  • Storage up to 1000 parts.
  • Automatic system voltage monitor for hipot.
  • Production counts are tallied and displayed on the right hand side of the computers main screen. Totals are kept for good, rejects, and tested.
  • Statistical failure analysis reporting in number and percentages.
  • Full color graphics display.All instructions and test results are displayed on this monitor. The entire software program has a clear and precise fault messaging system. Each testers screen is customized for the individual application.
  • Drawer mounted keyboard.
  • Visual test results on screen.
  • Printer output. A printer may be connected to the tester to print out test set-up information and test results from each part. You will have the ability to print out all test data, good parts only, or reject parts only.
  • Operator Interface. All messages and text displayed on the video monitor will be in English. Other languages are available as an option.
  • Networking and SPC capabilities.
  • Mounted on casters for portability.
  • Password Software Interface provides tighter restrictions on who is accessing the systems software.
  • Data Logging Automatically gather and stores test data, by date and time stamp, for all parameters on all parts tested.
  • Data Viewer. This utility gives the user the opportunity to view the test data in a spreadsheet style layout (Comma delimited files).
  • Manual mode of operation is provided for set-up or evaluation. Test time in the manual mode is indefinite and many of the test steps can be individually selected.
  • Modem installed with our diagnostic software, which allows us to dial directly into the tester to perform remote diagnostics, changes and software upgrades
Optional Equipment/Software
  • Remote Workstations. A remote workstation allows for the testing of parts at a remote line or cell. The workstation can be built as a single or dual station unit and can be located up to 60 feet away from the tester.
  • Attached Workstations.The on-board or attached workstations allows for the testing of parts at the testers location. The workstation is permanently attached to the tester. The workstation can be built as a single or dual station unit
  • Dual Station Testing Capabilities. Dual station testing permits the your operator to load a part into one station while the other station is testing. This option will significantly increase the output of the tester. Dual station can be utilized with either remote or on-board workstations. Two test fixtures are required.
  • Dual Limits Testing Capabilities. Dual limits testing permits you to test two completely different motors at the same time. (The dual station testing option is also required.) This option is best suited for when volumes are not too high or in a cellular type manufacturing environment.
  • Automation Testing Capabilities. Output closures and software permit the tester to be integrated into your production line.
  • Bar Code Reading Capabilities. This option will allow you to add a bar code reader to the tester. This reader would scan a bar code label to determine the correct model to test.
  • Label Printing Capabilities. Enables "Good" or "Reject" labels to be printed after the testing sequence has completed. Additional information can be added to these labels.

Experience has taught us that when it comes to motor testing, every customer is truly different. As a result we do not manufacture a one-size-fits-all motor tester. Instead, we design each system based on the requirements and budget constraints of the individual customer.

To request a quotation, click here and fill in the requested information
or you can call us at 262-554-1211